Electrical connectors – Metallic connector or contact having part permanently...
Reexamination Certificate
1999-04-16
2001-06-19
Nguyen, Khiem (Department: 2839)
Electrical connectors
Metallic connector or contact having part permanently...
C439S492000
Reexamination Certificate
active
06247977
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to a connector for connecting between a flat cable and two electric wires, connecting structure and connecting method.
Between a relatively freely rotatable steering wheel and a steering column there is disposed an electric connection device (Japanese Patent Application Laid-Open Publication No. H 9-102337, to which refer). A general electric connection device is equipped with a rotary body fixed to a steering wheel side, a stationary body fixed to a steering column side, a flat cable for making connection between the rotary body and stationary body, and a connector for connecting between an end portion of the flat cable and an electric wire.
The connector is equipped with a holder, a plurality of bus bars insert molded in the holder, and insulating walls between the bus bars that are formed integrally with the holder.
Conductor portions of the flat cable are disposed between core wire portions of the electric wire and the bus bars. An anvil is applied to the underside of the bus bars and, from above the core wire portion of the electric wire, an ultrasonic welding jig is inserted between the insulating walls. Then, the jig is pressed against the core wire portion, whereby the core wire portions are ultrasonically welded to the bus bars jointly with the conductor portions.
SUMMARY OF THE INVENTION
In the case of the above-described conventional connector, the size of the jig is limited to a range enabling the jig to be inserted into between the insulating walls. For this reason, in a case where the core wire portion is located at a position deviated from the position at which the core wire portion is preset, or where the core wire portion is not sufficiently twisted, there is the possibility that the core wire portion will get out of the position corresponding to the bus bar due to the pressing of the jig. The core wire that has gotten out of the bus bar is likely to further extend laterally (in the widthwise direction of the bus bar) due to the application thereto of the ultrasonic vibration energy and intrude into the insulating walls.
This intrusion phenomenon is difficult to discover through visual observation. When the core wire portion has deeply been intruded into the insulating walls, there is a fear that the insulation between the adjacent line circuits will fail to be maintained. Therefore, it is necessary to prevent the occurrence of such intrusion phenomenon and this makes the operation difficult to perform.
Especially, the increase in the number of signal line circuits due to an increase in the function of on-vehicle loaded appliances necessitates the performance of the connection within a limited space and hence the thinning in thickness of the insulating walls and the decreasing of the pitch between the line circuits. Therefore, the operation becomes further complex.
Accordingly, the object of the present invention is to provide a connector for a flat cable which makes it possible to ensure the insulation between the adjacent line circuits of the portions to be connected together through the performance of simple operations.
To attain the above object, the present invention is equipped with a resin-made holder and a cover mounted on the holder. The holder has two bus bars for electrical connecting a flat cable with two electric wires. Each the bus bar is insert molded in the holder and has a flat plate-like connecting portion. The connecting portions are arranged generally on a plane and spaced away from each other. The outer peripheral surface of each the connecting portion is exposed from the holder. The flat cable has two conductors. Each the conductor has an exposed conductor portion to be connected to each the connecting portion. Each the electric wire has a core wire portion to be connected to each the connecting portion by ultrasonic welding. A jig for use in ultrasonic welding presses the core wire portion toward the bus bar and generats ultrasonic waves. A space between the connecting portions prevents interference between the jig and the holder. The cover has an insulating wall inserted into the space between the connecting portions.
In the above-described construction, since the space between the connecting portions prevents the interference between the jig and the holder, the jig can be freely set to have a dimension and shape capable of preventing the deviation thereof from the core wire. For example, it is possible to form in the jig a recessed portion that comes in contact with the core wire portion as the recessed portion covers the core wire portion. As a result of this, the core wire portion is ultrasonically welded to the bus bar in a state of it being enclosed within the recessed portion and so the spreading thereof is suppressed with the result that the core wire portion is prevented from getting out of the bus bar.
Also, the space between the connection portions prevents the interference between the jig and the holder and so the operation of pressing the core wire portion by the jig and applying an ultrasonic wave energy is easy to perform.
Also, the outer periphery of the connection portion is exposed from the holder and so it is possible to easily confirm the ultrasonically welded connection portions with the naked eyes.
Further, the respective line circuits of the bus bars are isolated from each other by the insulating wall of the cover that is mounted on the holder after ultrasonic welding has been performed. Accordingly, the state of insulation between the adjacent line circuits is ensured against the vibration stress that occurs after loading onto a vehicle.
Each the exposed conductor portion may be arranged between each the connecting portion and each the core wire portions, and each the core wire portion may be connected to each the connecting portion by ultrasonic welding jointly with each the exposed conductor portion.
In this case, a recessed portion that opens wider than the width of the connecting portion and that comes in contact with the core wire portion as the recessed portion covers the core wire portion may be formed in the jig.
In the above-described construction, each the conductor portion, each the core wire portion, and each the connecting portion are collectively ultrasonically welded. At this time, the spreading of the core wire portion is suppressed, thereby enabling ultrasonic welding to be performed within the width of the bus bar.
REFERENCES:
patent: 5762507 (1998-06-01), Mochizuki et al.
patent: 5821465 (1998-10-01), Tanaka et al.
patent: 5857259 (1999-01-01), Johnston
patent: 5962813 (1999-10-01), Shirako et al.
patent: 6023022 (2000-02-01), Nakamura et al.
patent: 9-102337 (1997-04-01), None
Imai Taro
Tanaka Yoshiyuki
Finnegan Henderson Farabow Garrett & Dunner L.L.P.
Nguyen Khiem
Prasad Chandrika
Yazaki -Corporation
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